Installing a floor in the van

[getout]

Bondo and lots of it. We put bondo over all the screw holes, all the gaps/seems in the wood, over both fenders and the doghouse cover. Pretty much everywhere and anywhere there was any kind of crack or gap. The, came the sanding. The fastest way to sand down dried bondo...angle grinder. I started using a palm sander but it was taking too long. Busted out the angle grinder with a worn down grinding wheel and voila! It also knocked down the wood where it was higher than the piece next to it making the floor nice and smooth. You have to be a little careful over the glass, but you can get pretty detailed with the angle grinder.

Then, after the grinder takes down all the big ridges, it's time for sand paper.

[getout]

More bondo and sanding pictures

That's it for now. I've got Monday off so we're hoping to get the paint down.

[getout]

Got a lot more done. We finished getting everything sanded and prepped for paint. We used the Rustoleum Garage floor epoxy shield over the wood. It's not a thick as I thought it was going to be but it looks pretty good with the flakes spread out.

[getout]

More pictures

[getout]

More pictures

[getout]

And we threw a ladder on the back so I can quit climbing up the doors to get to the roof rack.

[WVvan]

Really impress job on the floor. I notice you have that hump in front of the doghouse. That's an advantage because when I tried to insulate the floor around my doghouse I found that it stopped me from removing the doghouse. Couldn't clear the new higher floor. Mines a 1999.

[GreyDawg]

Originally Posted by getout

And we threw a ladder on the back so I can quit climbing up the doors to get to the roof rack.

I need to put a ladder on my van -- where did you source yours?

And I'm glad to see that I'm not the only one foolish enough to do a conversion without a garage or workshop -- building on the apartment patio and in the parking lot!

Thanks,

GreyDawg

[my3kids]

GreyDawg,

For a budget ladder I purchased one from Amazon (no sales tax and free shipping) for Ford vans for $31.57. While its not as nice as some of the others it does the job. The top of the ladder hooks over the door. You can simply drill for the bottom or you can stretch it just a little so the ladder bottom reaches the bottom of the door. Being at the bottom can allow for a gusset if needed. The description is Surco 103HF94 Aluminum Van Ladder Hook, For Select Ford Vans.

Hope this helps™,
Ray + lovely wife + our 3 kids

[my3kids]

Oh, I forgot. That's a really nice floor.

Ray